Minebea Intec Weighbridge Load Cell PR 6221 Owner's manual

Truck scale load cell PR 6221

Installation Manual

Translation of the Original Installation Manual 9499 053 46800 Edition 1.11.0 07/29/2021

Minebea Intec GmbH, Meiendorfer Str. 205 A, 22145 Hamburg, Germany

Phone: +49.40.67960.303 Fax: +49.40.67960.383

Foreword

Must be followed!

Any information in this document is subject to change without notice and does not represent a commitment on

the part of Minebea Intec unless legally prescribed. This product should only be operated/installed by trained

and qualified personnel. In correspondence concerning this product, the type, name, and release number/serial

number as well as all license numbers relating to the product have to be cited.

Note

This document is partially protected by copyright. It may not be changed or copied, and it may not be used

without purchasing or written permission from the copyright owner (Minebea Intec). The use of this product

constitutes acceptance by you of the abovementioned provisions.

Table of contents

1 Introduction.........................................................................................................................................4

1.1 Read the manual.........................................................................................................................................................4

1.2 This is what operating instructions look like..........................................................................................................4

1.3 This is what lists look like...........................................................................................................................................4

1.4 This is what menu items and softkeys look like.....................................................................................................4

1.5 This is what the safety instructions look like..........................................................................................................4

1.6 Hotline.......................................................................................................................................................................... 5

2 Safety instructions...............................................................................................................................6

2.1 General notes ..............................................................................................................................................................6

2.2 Intended use................................................................................................................................................................6

2.3 Initial inspection..........................................................................................................................................................6

2.4 Before operational startup........................................................................................................................................6

3 Setup instructions................................................................................................................................ 7

3.1 Load cell arrangement............................................................................................................................................... 7

3.2 Selecting maximum capacity....................................................................................................................................8

4 Specifications ......................................................................................................................................9

4.1 Load cells .....................................................................................................................................................................9

4.1.1 Equipment supplied with the load cell .........................................................................................................9

4.1.2 General information ........................................................................................................................................9

4.1.3 Possible marking of the load cell for the Ex area...................................................................................... 10

4.1.4 Dimensions ..................................................................................................................................................... 10

4.1.5 Ordering information..................................................................................................................................... 11

4.1.6 Technical data.................................................................................................................................................. 11

4.2 Load disc kits............................................................................................................................................................. 14

4.2.1 General notes ................................................................................................................................................. 14

4.2.2 Equipment supplied ...................................................................................................................................... 14

4.2.3 Dimensions ..................................................................................................................................................... 18

4.2.4 Technical data................................................................................................................................................. 19

5 Installation.........................................................................................................................................20

5.1 Safety instructions....................................................................................................................................................20

5.2 Aligning the load cell.................................................................................................................................................21

5.3 Positioning upper load disc ....................................................................................................................................22

6 Connection......................................................................................................................................... 23

6.1 General information.................................................................................................................................................23

6.2 Load cell .....................................................................................................................................................................24

6.2.1 Load cell cable................................................................................................................................................24

6.3 Cable junction boxes................................................................................................................................................24

Truck scale load cell PR 6221 Table of contents

Minebea Intec EN-1

6.3.1 Lightning protection......................................................................................................................................25

6.4 Cable connections ....................................................................................................................................................25

7 Preparing for calibration.................................................................................................................... 27

7.1 General notes ............................................................................................................................................................27

7.2 Smart Calibration......................................................................................................................................................27

7.3 Mechanical height adaptation................................................................................................................................ 27

7.4 Corner load test ........................................................................................................................................................28

7.5 Electronic corner correction....................................................................................................................................28

7.6 Full load test and shift test......................................................................................................................................28

7.6.1 Full load test ...................................................................................................................................................28

7.6.2 Shift test ..........................................................................................................................................................29

7.6.3 Systematically minimizing shift error.........................................................................................................30

8 Troubleshooting ................................................................................................................................ 32

8.1 General Notes............................................................................................................................................................32

8.2 Visual inspection.......................................................................................................................................................32

8.3 Metrological controls...............................................................................................................................................32

8.3.1 Checking the zero output signal of the load cell.......................................................................................32

8.3.2 Checking the strain gauge bridge of the load cell....................................................................................33

8.3.3 Checking the insulation impedance of the load cell.................................................................................33

8.3.4 Checking the insulation impedance of the connecting cable.................................................................33

9 Maintenance/repairs/cleaning........................................................................................................... 34

9.1 Maintenance..............................................................................................................................................................34

9.2 Repairs........................................................................................................................................................................34

9.3 Cleaning .....................................................................................................................................................................34

10 Disposal ............................................................................................................................................. 35

11 Spare parts and accessories ............................................................................................................... 36

11.1 Replacement parts ...................................................................................................................................................36

11.2 Accessories ................................................................................................................................................................36

11.2.1 Mounting kits..................................................................................................................................................36

11.2.2 Load discs........................................................................................................................................................36

11.2.3 Connecting cables..........................................................................................................................................37

11.2.4 Cable junction boxes..................................................................................................................................... 37

11.2.5 Connexx module ............................................................................................................................................38

12 Certificates/safety instructions/control drawing...............................................................................47

12.1 BVS 16 ATEX E 005 ...................................................................................................................................................48

12.2 IECEx BVS 16.0005...................................................................................................................................................52

12.3 TÜV 03 ATEX 2301X..................................................................................................................................................56

12.4 IECEx TUN 17.0025X.................................................................................................................................................62

12.5 MIN16ATEX001X .......................................................................................................................................................66

Truck scale load cell PR 6221 Table of contents

EN-2 Minebea Intec

12.6 FM17CA0138..............................................................................................................................................................68

12.7 FM17US0276...............................................................................................................................................................71

12.8 4012 101 5688 ...........................................................................................................................................................74

12.9 MEU17025..................................................................................................................................................................75

12.10 RU Д-DE.A301.B.05345 ........................................................................................................................................... 81

12.11 D09-03.15 ..................................................................................................................................................................82

12.12 D09-00.23 .................................................................................................................................................................89

12.13 R60/2000-DE1-08.11...............................................................................................................................................98

12.14 NMI S333A ................................................................................................................................................................101

12.15 14-024A1 ...................................................................................................................................................................110

12.16 10001 .........................................................................................................................................................................113

Truck scale load cell PR 6221 Table of contents

Minebea Intec EN-3

1 Introduction

1.1 Read the manual

-Please read this manual carefully and completely before using the product.

-This manual is part of the product. Keep it in a safe and easily accessible location.

1.2 This is what operating instructions look like

1. - n. are placed before steps that must be done in sequence.

1.3 This is what lists look like

-indicates an item in a list.

1.4 This is what menu items and softkeys look like

[ ] frame menu items and softkeys.

Example:

[Start]- [Applications]- [Excel]

1.5 This is what the safety instructions look like

Signal words indicate the severity of the danger involved when measures for preventing

hazards are not followed.

DANGER

Warning of personal injury

DANGER indicates death or severe, irreversible personal injury which will occur if the

corresponding safety measures are not observed.

Take the corresponding safety precautions.

WARNING

Warning of hazardous area and/or personal injury

WARNING indicates that death or severe, irreversible injury may occur if appropriate

safety measures are not observed.

Take the corresponding safety precautions.

CAUTION

Warning of personal injury.

CAUTION indicates that minor, reversible injury may occur if appropriate safety

measures are not observed.

Take the corresponding safety precautions.

is placed before a step.

describes the result of a step.

Truck scale load cell PR 6221 1 Introduction

EN-4 Minebea Intec

NOTICE

Warning of damage to property and/or the environment.

NOTICE indicates that damage to property and/or the environment may occur if

appropriate safety measures are not observed.

Take the corresponding safety precautions.

Note:

User tips, useful information, and notes.

1.6 Hotline

Phone: +49.40.67960.444

Fax: +49.40.67960.474

eMail: [email protected]

1 Introduction Truck scale load cell PR 6221

Minebea Intec EN-5

2 Safety instructions

2.1 General notes

NOTICE

Warning of damage to property and/or the environment.

The product was in perfect condition with regard to safety features when it left the

factory.

To maintain this condition and to ensure safe operation, the user must follow the

instructions and observe the warnings in this manual.

2.2 Intended use

The load cell PR 6221 has been designed especially for use in truck scales.

The load cell PR 6221 may be used only for weighing tasks in truck scales as intended.

In intrinsically safe circuits, only load cells PR 6221/..E may be used.

The dimensions of all mounting and structural components must be calculated so that

sufficient overload capacity is ensured for all loads which may occur while taking the

relevant standards into account. In particular, upright weighing objects must be

safeguarded against the weighing installation turning over or being shifted, thus

eliminating danger to people, animals, or goods even in the case of a break in a load cell

or mounting element.

Installation and repair work must only be carried out by expert/qualified personnel.

The load cell reflects the state of the art. The manufacturer does not accept any liability

for damage caused by third-party system components or due to incorrect use of the

product.

2.3 Initial inspection

Check the contents of the consignment for completeness. Check the contents visually to

determine whether any damage has occurred during transport. If there are grounds for

rejection of the goods, a claim must be filed with the carrier immediately. The

Minebea Intec sales or service organization must also be notified.

2.4 Before operational startup

NOTICE

Perform visual inspection.

Before operational startup as well as after storage or transport, inspect the load cell

visually for signs of mechanical damage.

Truck scale load cell PR 6221 2 Safety instructions

EN-6 Minebea Intec

3 Setup instructions

3.1 Load cell arrangement

Key

Load application

Stop

A 5 mm

-The supporting structure of the scale (and thus the load cells) as well as the

weighbridge must be stable enough to withstand the specified loads, horizontal

(check with spirit level!) and flat.

-Transverse and/or horizontal forces and torques exceeding the permissible limits are

disturbances which can generate measuring errors and, in the worst case, may

damage the load cell.

-If stops are used, damage and measuring errors can be prevented without affecting

the required space for movement in the direction of the measurement.

The lateral play of the weighbridge must always be restricted to the distance "A" (see

figure) in the longitudinal and transverse direction by appropriate stops.

Consideration should be given to the fact that thermal expansion and contractions

may constrict the required space for movement of the object to be weighed and

could thereby lead to significant falsification of the measuring results.

3 Setup instructions Truck scale load cell PR 6221

Minebea Intec EN-7

3.2 Selecting maximum capacity

Forces exceeding the safe load limit Elim in the measuring direction may change the

characteristics of the load cell or damage it.

If the safe load limit Elim of the load cell can be exceeded, e.g. by falling loads, then

mechanical limiting in load direction is strongly recommended.

If the destructive load Edof the load cell is exceeded, there is danger of mechanical

destruction.

Truck scale load cell PR 6221 3 Setup instructions

EN-8 Minebea Intec

4 Specifications

4.1 Load cells

4.1.1 Equipment supplied with the load cell

No. Description

1 Load cell

2 Quick guide

3 Calibration Certificate

4 Only with Ex-load cells:

Safety information for Ex-load cells

4.1.2 General information

Restoring force For each mm of displacement that the top of the load cell is shifted from the vertical

axis, a horizontal restoring force of 1.55% of the load resting vertically on the load cell

is generated per millimeter deflection (measured at the load cell head).

Material for load cell

housing

Stainless steel 1.4301 acc. to DIN EN 10088-3 (corresponds to AISI 304, B.S. 304S11/

S15)

Protection against en-

vironmental influences

Hermetically sealed by welding.

Filled with inert gas.

Protection classes in compliance with IEC 529 or DIN EN 60529 IP66/IP68/IP69,

in compliance with ISO 20653 IP6K6K/IP6K8/IP6K9K:

Dust-proof and leak-tight against water, with harmful effects when immersed, (1.5 m

water depth, 10,000 h) and water jets (high pressure and temperature).

Explosion:

Suitable for explosion subgroup IIC and IIIC.

Protection type Intrinsic safety for PR 6221/..E

Ambient temperature in

the Ex area

see additional information “safety instructions for Ex load cells”

Cable diameter 5 mm

Cable length Standard version: 16 m

Ex version: 20 m

Cable gauge 4×0.35 mm2

Cable bend radius ≥25 mm (fixed installation)

≥75 mm (flexible installation)

Cable sheath material Thermoplastic elastomer (TPE)

Cable sheath color Green (standard version)

Blue (Ex version)

4 Specifications Truck scale load cell PR 6221

Minebea Intec EN-9

4.1.3 Possible marking of the load cell for the Ex area

Zone Marking Certificate no. for

0 and 1 II 1G Ex ia IIC T6 Ga

Ex ia IIC T6 Ga

BVS 16 ATEX E 005

IECEx BVS 16.0005

only PR 6221/..E

20 and 21 II 1D Ex ta IIIC T160 °C Da

Ex ta IIIC T160 °C Da

TÜV 03 ATEX 2301X

IECEx TUN 17.0025X

all PR 6221 without

/..E

2 II 3G Ex nA IIC T6 Gc MIN16ATEX001X all PR 6221 without

/..E

22 II 3D Ex tc IIIC T85 °C Dc MIN16ATEX001X all PR 6221 without

/..E

IS CL I, II, III, DIV 1, GP A, B, C, D, E, F, G Entity -

4012 101 5688

NI CL I, II, III, DIV 2, GP A, B, C, D, E, F, G - 4012

101 5688; NIFW

T4A Ta= -40°C to 70°C; T5 Ta= -40°C to 55°C

FM17US0276 all PR 6221 without

/..E

IS CL I, II, III, DIV 1, GP A, B, C, D, E, F, G Entity -

4012 101 5688

NI CL I, II, III, DIV 2, GP A, B, C, D, E, F, G - 4012

101 5688; NIFW

T4A Ta= -40°C to 70°C; T5 Ta= -40°C to 55°C

FM17CA0138 all PR 6221 without

/..E

NOTICE

Installation in the Ex area

For installations in the Ex area, it is imperative to observe the Ex safety instructions in the installation

manuals.

4.1.4 Dimensions

all dimensions in mm

Truck scale load cell PR 6221 4 Specifications

EN-10 Minebea Intec

4.1.5 Ordering information

Model Max. capacity

Emax

Type

PR 6221/12.5 t 12.5 t ..C3/C3E/C4/C4E

PR 6221/20 t 20 t ..C3/C3E/C4/C4E/C5/C5E/C6/C6E

PR 6221/25 t 25 t ..C3/C3E/C4/C4E/C5/C5E/C6/C6E

PR 6221/30 t 30 t ..C3/C3E/C4/C4E/C5/C5E/C6/C6E

PR 6221/50 t 50 t ..C3/C3E/C4/C4E/C5/C5E/C6/C6E

PR 6221/60 t 60 t ..C3/C3E/C4/C4E/C5/C5E/C6/C6E

PR 6221/75 t 75 t ..C3/C3E/C4/C4E/C5/C5E/C6/C6E

4.1.6 Technical data

Designation Description Abbr. C3 C4 C5 C6 Unit

Accuracy class 0.015 0.012 0.010 0.008 % Emax

Minimum dead load lowest limit of specified measu-

ring range

Emin 0 % Emax

Maximum capacity highest limit of specified mea-

suring range

Emax see Chapter 4.1.5

Highest load without irreversib-

le damage

Emax = 12.5 t Elim 37.5 37.5 … … t

Emax = 20 t Elim 40 t

Emax = 25 t Elim 37.5 t

Emax = 30 t Elim 60 t

Safe load limit

Emax = 50, 60, 75 t Elim 75 t

danger of mechan. destruction

Emax = 12.5 t Ed>75 >75 … … t

Emax = 20 t Ed>100 t

Emax = 25 t Ed>75 t

Emax = 30 t Ed>150 t

Destructive load

Emax = 50, 60, 75 t Ed>150 t

Minimum LC verifi-

cation

minimum load cell scale inter-

val, vmin = Emax/Y

Y 14000 20000 20000 20000

recurrence of the minimum pre-

load signal (DR = ½×Emax/Z)

Z 6000 8000* 8000* 8000*

Emax ≥50 t Z 6000 6000 6000

Minimum preload si-

gnal recurrence

* Z = 8000 at -10°C…+40°C; Z = 6000 above +40°C

4 Specifications Truck scale load cell PR 6221

Minebea Intec EN-11

Designation Description Abbr. C3 C4 C5 C6 Unit

relative output signal at maxi-

mum capacity

Emax = 12.5 t Cn1.0 1.0 … … mV/V

Emax = 20, 30 t Cn1.0 mV/V

Emax = 25 t Cn2.0 mV/V

Emax = 50 t Cn2.0 2.0 1.5 1.5 mV/V

Emax = 60 t Cn2.4 1.5 1.5 1.5 mV/V

Rated output

Emax = 75 t Cn3.0 1.5 1.5 1.5 mV/V

Tolerance on rated

output

permissible deviation from ra-

ted output Cn

dc<0.07 % Cn

Zero output signal load cell output signal under un-

loaded condition

Smin 0 ±1.0 % Cn

Reproducibility max. change in load cell output

for repeated loading

ɛR<0.005 % Cn

Creep max. change of output signal at

Emax during 30 minutes

dcr <0.015 <0.0125 <0.010 <0.008 % Cn

Non-linearity1) Deviation from the best straight

lines through zero

dLin <0.01 <0.01 <0.01 <0.01 % Cn

Hysteresis1) max. difference in LC output

between loading and unloading

dhy <0.0165 <0.0125 <0.010 <0.008 % Cn

Temperature effect

of the Smin

max. change of Smin in BTTKSmin <0.01 <0.007 <0.007 <0.007 % Cn/10 K

Temperature effect

on C1)

max. change of C in BTTKC<0.01 <0.008 <0.007 <0.005 % Cn/10 K

Input impedance between supply terminals RLC 1080±10 Ω

between measuring terminals RO1010±1 Ω

Emax = 50 t RO1010±1 1010±1 760 ±1 760 ±1 Ω

Emax = 60 t RO1010±1 635 ±1 Ω

Output impedance

Emax = 75 t RO1010±1 510 ±1 Ω

Insulation impedan-

ce

between measuring circuit and

housing, UDC = 100 V

RIS >5000 MΩ

Insulation voltage between circuit and housing

(PR 6221/..E only)

500 V

Recommended sup-

ply voltage

to hold the specified perfor-

mance

Bu4 to 24 V

permissible for continuous ope-

ration without damage

Umax 32 VMax. supply voltage

for PR 6221/..E: Umax 25 V

Truck scale load cell PR 6221 4 Specifications

EN-12 Minebea Intec

Designation Description Abbr. C3 C4 C5 C6 Unit

Nominal ambient

temp. range

to hold the specified perfor-

mance

BT-10 to +55 °C

Service temperature

range

permissible for continuous ope-

ration without damage

BTu -40 to +95 °C

Storage temperature

range

without electrical and mechani-

cal stress

BTi -40 to +95 °C

Permissible eccentri-

city

permissible displacement from

nominal load line at the head of

the load cell

Sex 5 mm

Vibration resistance Resistance against oscillations

(IEC 60068-2-6 Fc)

20 g, 100 h, 10 to 150 Hz

Barometric pressure

influence

influence of barometric pressu-

re on output

PKSmin 420 g/kPa

elastic deformation under maxi-

mum capacity

Emax = 12.5 t Snom 0.2 0.2 … … mm

Emax = 20 t Snom 0.4 mm

Emax = 25 t Snom 0.5 mm

Emax = 30 t Snom 0.5 mm

Emax = 50 t Snom 0.8 mm

Emax = 60 t Snom 0.9 mm

Nominal deflection

Emax = 75 t Snom 1.1 mm

1) The data for non-linearity (dLin), hysteresis (dhy) and and temperature effect on C (TKC)

are typical values.

For OIML R60 or NTEP approved load cells the sum of these values is within the per-

missible cumulative error limits.

Definitions acc. to OIML R60

The technical data given are intended solely as a product description and should not be

interpreted as guaranteed properties in the legal sense.

NTEP: min. scale interval of the load cells vmin

Type Divisi-

ons

nmax

12.5 t 20 t 25 t 30 t 50 t 60 t 75 t Unit

Class III

L Multi-

ple

C3 10000 0.43 0.48 0.60 0.71 1.19 1.43 1.79 kg

4 Specifications Truck scale load cell PR 6221

Minebea Intec EN-13

4.2 Load disc kits

4.2.1 General notes

Note:

The load disc kit is not included in the equipment supplied with your load cell.

For the order numbers of the load disc kits, please refer to Chapter 11.2.2.

4.2.2 Equipment supplied

4.2.2.1 Load disc kit PR 6021/00N

No. Description

1 Upper load disc

2 Flexible copper strap

3 Lower load disc

4 Supporting ring

Truck scale load cell PR 6221 4 Specifications

EN-14 Minebea Intec

4.2.2.2 Load disc kit PR 6021/02N

No. Description

1 Upper load disc

2 Flexible copper strap

3 Lower load disc

4 Supporting ring

5 Anti-twist protection

4 Specifications Truck scale load cell PR 6221

Minebea Intec EN-15

4.2.2.3 Load disc kit PR 6021/04N

No. Description

1 Turbo Load disc

2 Flexible copper strap

3 Lower load disc

4 Supporting ring

Truck scale load cell PR 6221 4 Specifications

EN-16 Minebea Intec

4.2.2.4 Load disc kit PR 6021/06N

No. Description

1 Turbo Load disc

2 Flexible copper strap

3 Lower load disc

4 Supporting ring

5 Anti-twist protection

4 Specifications Truck scale load cell PR 6221

Minebea Intec EN-17

4.2.3 Dimensions

PR 6021/00N, ../02N

all dimensions in mm

Truck scale load cell PR 6221 4 Specifications

EN-18 Minebea Intec

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Minebea Intec Weighbridge Load Cell PR 6221 Owner's manual

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